How Kashyap Auto-BFSR Reduced Cooling Tower Blowdown from 2850 KL to 21 KL at Vignesh Hitech City 2

Vignesh Hitech City 2 is a large commercial building located in Hitech City, Hyderabad. The building manages blocks supported by a centralised HVAC cooling tower and chiller system to meet continuous cooling and comfort requirements.

HVAC cooling tower/chiller system

The HVAC cooling tower and chiller system at Phoenix H04 Block, Vignesh Hitech City 2, Hyderabad, was operating under high-TDS makeup water conditions, resulting in persistent scale formation and biofouling across the cooling tower, heat exchange surfaces, and connected utility pipelines.

The system was forced to operate inefficiently because the only water available to add was very dirty (2500 ppm), but the cooling tower could only handle water that was relatively clean (600-700 ppm).

In addition to HVAC inefficiencies, scale deposition became a concern, increasing maintenance costs and operational risks across the building.

To eliminate persistent scaling and biofouling in the cooling system, reduce excessive water consumption caused by high-blowdown operations, and protect the broader building utility network from mineral deposits, ensuring reliable chiller performance and lower maintenance costs.

Kashyap Auto BFSR was installed on the HVAC cooling tower system to address scale and biofouling at the source through continuous, chemical-free operation.

Post-installation, the system enabled stable operation at normal TDS levels without scale deposition, allowing the cooling system to run at improved cycles of concentration while significantly reducing blowdown requirements. Scale formation was eliminated across the cooling towers and the entire cooling water circulation system, resulting in improved chiller efficiency and optimum HVAC performance.

After implementing Kashyap AUTO BFSR, energy consumption drops from 0.85–1.0 kW/TR to 0.60–0.65 kW/TR, while total water blowdown over 10 months falls from 2,850 KL to just 21 KL.

Also, the facility achieved measurable water savings, improved system reliability, reduced maintenance intervention, and long-term operational stability, validating the effectiveness of the Auto BFSR system in high-TDS HVAC applications.